White Rodgers TW2000 User Manual

TW2000  
WOOD-FIRED BOILER  
OWNER’S MANUAL  
IMPORTANT  
READ OWNER’S MANUAL THOROUGHLY BEFORE  
INSTALLING BOILER OR LIGHTING FIRE.  
CONSULT LOCAL AUTHORITIES IF IN DOUBT  
ABOUT YOUR LOCAL FIRE SAFETY REGULATIONS.  
ALL INSTALLATIONS MUST BE MADE IN  
ACCORDANCE WITH LOCAL AND STATE OR  
PROVINCIAL CODES WHICH MAY DIFFER FROM  
THIS MANUAL.  
IMPROPER INSTALLATION WILL RESULT IN  
VOIDING OF WARRANTY.  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
SECTION 1 – OPERATING INSTRUCTIONS  
KERR TW2000 Wood-Fired Boiler  
Tested by: Warnock Hersey Professional Services Ltd. to CSA standard B366.1  
Certified by the  
Canadian Standards Association (CSA) May 1984  
COSP. WWP-009  
Manufactured by: Parrsboro Metal Fabricators Ltd.  
P.O. Box 637, Crossroads  
12118 Highway 209  
Parrsboro Nova Scotia, Canada  
B0M 1S0  
Specifications  
Cabinet  
Length  
Width  
36”  
22”  
Height  
36”  
Shipping Weight  
Fire Box  
600 lb.  
36”  
Length  
Width  
16”  
Height  
26”  
Water Volume  
US Gallons  
IMP. Gallons  
Liters  
26.10  
21.73  
98.80  
Heat Exchanger  
Fire Box Door  
Supply  
3/16” & 12-gauge steel  
13” x 13”  
1 ¼”  
Cast Iron  
Return  
1 ¼”  
Smoke Pipe  
Smoke pipe exit  
Output (max):  
Fuel:  
Boiler Water Volume  
Domestic Hot Water Coil  
Electrical Rating:  
7” Inside Diameter  
Top  
70,000 Btu/h  
Wood 30” logs maximum  
26.0 U.S. gal.  
Optional  
Volts 120, 15Amps  
NOTE – Keep this manual in a safe place for future reference. Follow manual  
carefully for the correct way to install and operate this unit.  
CAUTION – Do not fire this unit until operating instructions have been read and  
fully understood.  
INSTALL WOOD-FIRED BOILER ONLY ON A FLUE SYSTEM AND CHIMNEY  
THAT ARE IN GOOD CONDITION.  
SAVE THESE INSTRUCTIONS  
TW2000  
2
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
SECTION 1 – OPERATING INSTRUCTIONS  
1.1 Introduction  
Congratulations on your purchase of the KERR TW2000 Wood-Fired Boiler.  
Developed in Atlantic Canada, this KERR Boiler has been designed to allow you  
to heat your home with wood, one of North America’s most abundant fuels. The  
heat exchanger materials meet ASME (American Society of Mechanical  
Engineers) requirements for domestic boilers. Designed with you in mind, the  
KERR TW2000 Wood-Fired Boiler will provide you with many years of safe,  
efficient central heating.  
To ensure you have a clear understanding of the operating procedures of this  
boiler, please take the time to read the remainder of this section on operating  
procedures. If you have any questions, your KERR DEALER will be happy to  
answer them for you.  
1.2 Wood-Burning  
The TW2000 Wood-Fired Boiler will burn most wood fuels, however it is  
recommended that only dry seasoned hardwood be used as much as possible  
since it affords cleaner, safer and more efficient operation. Burning seasoned  
hardwood will leave less ash, soot and creosote residue and will require fueling  
less often. Use smaller loads of wood on warmer days.  
WARNING: DO NOT use chemicals or fluids to start the fire or during operation.  
DO NOT burn driftwood or manufactured logs (compressed wood).  
Before adding fuel to an existing fire turn up the thermostat for about five minutes  
or lift damper chain to hold damper fully open for about one minute before  
opening the loading door. This action will allow residual smoke to clear from the  
combustion chamber and reduce smoke entering the basement during refueling.  
Twice daily refueling may be sufficient in modern well-insulated homes.  
However, KERR recommends that small fuel loads be added morning, noon and  
early evening and late evening, rather than large quantities infrequently. A small  
intense fire will burn more efficiently than a large smoldering fire in the TW2000  
Wood-Fired Boiler and will produce less creosote.  
When refueling the TW2000, the remaining coals should be raked to the front of  
the combustion chamber before adding any new fuel. New fuel shall be placed  
on and behind the hot coals. This will help create a more even and efficient burn.  
The TW2000 owner should attempt to gauge fuel quantities with outdoor  
temperatures; a little practice will provide greater satisfaction and efficiency.  
WARNING: This Boiler is not to be used with an automatic stoker.  
Keep firing door tightly closed and maintain door seal in good condition.  
TW2000  
3
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
IN CASE A SERIOUS CREOSOTE FIRE BEGINS:  
a)  
b)  
c)  
d)  
Close the damper door by disconnecting chain  
Close all draft regulators  
Throw ½ lb, of coarse or table salt on the fire and reclose door immediately.  
Call the FIRE DEPARTMENT at once!  
Have a firmly established Emergency Procedure in place for the handling of a flue  
fire.  
CREOSOTE  
Wood combustion is never 100% complete. Wood smoke always contains some  
unburned gases and a mixture of unburned tar-like liquids. A percentage of  
these materials will condense out on any cool surface, leaving a dark brown or  
black substance with an unpleasant acrid odour. This substance is commonly  
called creosote.  
If these wood gases condense out on cool surfaces such as a cold chimney or a  
long smoke pipe they retain large amounts of water and will be very fluid. At  
higher temperatures the condensed creosote will resemble tar (thick and tacky).  
Creosote generation is highest during low heat outputs common with long  
smoldering burns. Creosote generation is lowest during high heat outputs  
common with intense fires. It is recommended that a small intense fire be used  
for best results against creosote build up even though the Wood-Fired Boiler will  
require refueling more often.  
Creosote generation is also higher when burning green wood. The moisture in  
the green wood absorbs the heat from the fire, cooling the fire below the point at  
which the creosote can be consumed. The low temperature smoke is then  
further cooled in the upper boiler chamber; smoke pipe and chimney allowing  
large amounts of creosote to form.  
To reduce creosote build-up during periods of low heat requirements (i.e Spring  
and Fall) it is recommended to fuel the Wood-Fired Boiler with smaller quantities  
of smaller diameter logs. Matching fuel loads and heat requirements will result in  
cleaner combustion and higher efficiency.  
1.3 Storage of Wood  
Once cut, green wood dries (or seasons), quickly at first and then at a slower  
rate. When the wood has been cut to the proper length and split, it should be  
piled outside during the summer months. Place two poles on the ground to serve  
as rails to keep the firewood off the moist ground. Stack the wood so that both  
ends of the logs are exposed to the air if space is available, since more drying  
occurs through the cut ends than through the sides. This is true even with wood  
that has been split. The woodpile should be under cover so that it will not absorb  
moisture from the rain and snow before it is used, but still open on the sides and  
ends to the drying effect of the wind and sun. Store wood in neat, well-supported  
piles.  
TW2000  
4
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
DO NOT store wood within installation clearances or within the space required  
for charging or ash removal.  
1.4 Maximum Solid-Fuel Charge  
The maximum level for a solid-fuel charge is the middle of the loading door, or  
the level of the handle. DO NOT overfill or extreme over-heating may result,  
causing warpage or damage to the boiler.  
The KERR TW2000 Wood-Fired Boiler will accept whole or split logs up to 34 in.  
(864 mm) long, but a 30 in. (762 mm) log length is recommended for  
convenience and ease in handling.  
Maximum damper gate opening is 11/16”. Do not tamper or adjust to greater  
opening in an attempt to increase fire or over-firing and hazard may result.  
1.5 Maintenance  
Some regular maintenance is necessary on the KERR TW2000 boiler. A good  
practice is to establish a routine for the storage of fuel, care of the appliance, and  
firing techniques.  
1.5.1 Cleaning  
The KERR TW2000 Wood-Fired Boiler must be cleaned regularly to maintain top  
efficiency. The boiler needs cleaning more often when burning green wood, or  
during long periods of low fire. When the KERR TW2000 Wood-Fired Boiler is  
first installed the boiler heat exchanger should be checked visually from the  
firebox and smoke pipe hole every week to determine the rate at which creosote  
or ash is accumulating within the Boiler. Cleaning should be done whenever  
there is more than ¼ inch of build-up on the heat exchanger or 3 inches of ash in  
the base.  
CLEANING PROCEDURE:  
(1)  
(2)  
(3)  
(4)  
(5)  
Make sure fire is completely out and the Boiler has cooled.  
Remove the smoke pipe located on the top of the Boiler.  
Remove the overhead baffle in the combustion chamber if necessary.  
The heat exchanger is now accessible for cleaning.  
Use the scraper provided to remove all soot and ash from the boiler heat  
exchanger and exposed surfaces.  
(6)  
(7)  
(8)  
Always check flue pipe for creosote or ash build-up in the pipe and clean if  
necessary.  
Reinstall smoke pipe making sure that all joints are secured with at least 3  
sheet metal screws. Also reinstall the overhead baffle.  
Check chimney cleanout for ash build-up and remove any accumulation.  
TW2000  
5
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
(9)  
Residue may be removed from the firebox or left to be burned during the  
next fire. It is good practice to leave a layer of ash approximately one inch  
deep in the base of the firebox.  
DISPOSAL OF ASHES  
Ashes should be placed in a metal container with a tight fitting lid. The closed  
container of ashes should be placed on a non-combustible floor or on the ground,  
well away from all combustible materials, pending final disposal. If the ashes are  
disposed of by burial in soil or otherwise locally dispersed, they should be  
retained in the closed container until all cinders have thoroughly cooled.  
WARNING – Ashes usually contain live dormant coals, which may burn for many  
hours after a recognizable flame has disappeared. Use extreme caution when  
handling and disposing ashes.  
IMPORTANT – No other waste shall be placed in this container.  
1.6 Safety  
If the boiler overheats due to improper operation the following precautions should  
be taken:  
(1)  
DO NOT shut off power. The circulation pump must be kept running to  
disperse excessive heat.  
(2)  
(3)  
Manually close the damper door by unhooking the chain.  
Increase all thermostats in the house to maximum to help disperse  
excessive heat.  
(4)  
Excessive heat caused by extreme over-firing or a control malfunction  
may cause the relief valve to blow off water/steam into the firebox. Do not  
be alarmed. The relief valve will reseat when the excessive pressure has  
been released.  
(5)  
Do not add more fuel until you are certain that all controls are functioning  
properly and no damage has been done to the boiler.  
WARNING – The maximum opening of the combustion air damper is preset at  
the factory. DO NOT adjust the stop or attempt to increase the  
combustion air by any means.  
TW2000  
6
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
1.7 Electrical Power Failure  
If no one is home during a power failure, the safety bypass zone valve will  
automatically open and some gravity heating will take place. The damper door  
will automatically close, but combustion air will continue to enter through the  
secondary air holes and a fire should be maintained. For optimum heating during  
a power failure follow the procedure listed below:  
(1)  
(2)  
(3)  
Manually open all zone valves and flow check valves to allow  
gravity flow to all areas. (Check with your installer)  
Place a coin under the damper flap in such a way that it will fall  
clear when power is restored and the damper motor operates.  
Maintain a careful watch on the boiler water temperature. If it  
should exceed 200º F (95º C) close the damper door.  
(4)  
(5)  
Do not leave the boiler unattended in this position.  
Refuel frequently with a small load to maintain a small fire at ½  
normal maximum volume.  
(6)  
(7)  
Do not expect to maintain maximum comfort under no power  
conditions.  
Do not allow anyone who is unfamiliar with the operation of the  
Boiler to attend it during a power failure.  
TW2000  
7
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
1.8 HOMEOWNER CHECKLIST  
(a)  
(b)  
Keep area around TW2000 boiler clean and clear of combustibles.  
Use only dry wood. DO NOT burn garbage, gasoline, naphtha  
engine oil or any other combustible liquid.  
(c)  
(d)  
(e)  
(f)  
Remove ashes as directed.  
Watch for soot in smoke pipe – clean regularly.  
Clean Boiler heat exchanger regularly.  
Be aware of danger due to overfiring unit.  
(g)  
Do not load above maximum loading level (middle of loading door)  
or overheating may result.  
(h)  
(i)  
This unit is NOT suitable for automatic stoking.  
Load carefully. Do not slam fuel against rear or sides of firebox.  
This may damage the brick lining. See fig. TW-7 to order and install  
replacement firebrick.  
(j)  
Always observe the following minimum clearances to combustible  
materials – Front 48” (1220 mm); one side 6” (152 mm); opposite  
side and rear 24” (610 mm); and flue pipe 18” (465 mm) and the  
floor must be non-combustible.  
(k)  
(l)  
Do not store solid fuel within the above clearances or within the  
space required for charging and ash removal.  
Keep firing door closed and maintain seals in good condition.  
(m) Establish a routine for storage of fuel, care of the appliance, and  
firing techniques.  
TW2000  
8
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
SECTION 2  
INSTALLATION INSTRUCTIONS  
TW2000  
9
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
SECTION 2 – INSTALLATION INSTRUCTIONS  
2.1 Introduction to Installers  
Before installing this KERR TW2000 Wood-Fired Boiler, please read the  
following instruction manual carefully. This unit is designed to be a freestanding  
central heating boiler, or as an add-on to operate in conjunction with an existing  
oil, gas, or electric unit, to provide complete central heating in medium sized well-  
insulated homes. Before installing be sure unit is properly sized for the intended  
application. Warranty does not cover misapplication of unit.  
Applicable Standards  
The KERR TW2000 Wood-Fired Boiler must be installed in accordance with the  
requirements of the National Fire Protection Association codes, the Canadian  
Heating, Ventilation and Air Conditioning Code, The National Board of Fire  
Underwriters, and the C.S.A. Standards for solid fuel burning equipment as  
outlined in B365-01. In all cases consult your local authorities and fire insurance  
company for specific regulations.  
2.2 Uncrating  
When you receive your TW2000 Wood-Fired Boiler, check it carefully to ensure  
that all components are present and in good condition. If there has been any  
damage or loss in transportation, please notify the carrier and retailer at once.  
NOTE: Some parts may be packed inside boiler firebox.  
Inspect for the following:  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
10.  
Firebox/Heat exchanger  
Poker/Coals rake  
Cabinet  
Barometric damper  
Firebrick (Factory installed in base) See fig. TW-7 for detail.  
Front insert  
Overhead baffle  
Cast door handle assembly  
Controls package  
Optional domestic hot water coil  
Control Package includes:  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
Dual aquastat, ½” well  
Single aqustat wt well ½”  
Damper Motor  
N/O Zone valve, and fittings  
Pressure relief valve  
Tridicator  
Transformer 120/24V  
Wiring Harness and Parts  
Black iron and copper fittings  
TW2000  
10  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
2.3 Locating the Boiler  
The location of the Boiler must be as close as possible to the tile-lined brick  
chimney, or factory-built solid-fuel approved chimney (ULC S629). Keep in mind  
also the day-to-day operation, and place for ease of fueling and cleaning.  
To lighten the boiler for placement, all parts including firebrick and baffles can be  
removed.  
It is important to provide adequate combustion air to the Boiler. It may be  
necessary to add a ventilator to an exterior wall of a closed Boiler room or an  
airtight basement.  
The Boiler must be installed so that the clearances on page 13, or those of local  
authorities are met. If the Boiler must be installed on a combustible floor, a non-  
combustible base must be built as shown in Figure TW - 8. Two layers of hollow  
masonry block (4” thick) are placed at right angles to each other so that the  
ventilation holes of one layer are opposite to those of the other layer. Also for  
ember protection, there must be a minimum one layer of 26 ga. galvanized metal  
beneath the masonry blocks. This base must extend beyond the Boiler to a  
minimum distance of 18 in (457 mm) in front and 8 in. (204 mm) on all sides.  
With the location of the boiler selected the next step is to position the unit and  
proceed with assembly. If a noncombustible base is not required Kerr  
recommends that the boiler be placed on masonry blocks (bricks or 8”concrete  
blocks) if space permits, to allow easier fueling and to keep the KERR TW2000  
boiler above any possible water in the basement. These blocks should extend  
approximately 1” on all sides of the boiler to support the cabinet. Continue as  
follows:  
1.  
Plan all plumbing and electrical runs so that flue pipe is easily  
removable for cleaning and to permit movement in the area as  
necessary.  
2.  
3.  
Position masonry blocks and place the unit on top. Level the blocks as  
necessary.  
Install the domestic coil if it is to be used, after removing the blank  
plate.  
4.  
5.  
Set the loading door in place on the hinges.  
Install aquastat wells, tridicator and pipe fittings using good quality pipe  
thread sealant or Teflon tape (Fig. TW-9).  
6.  
7.  
Set each side panel in place with bottom of panel hooking over boiler  
base rail angle. Top fits down over sides and boiler. A perfect fit may  
be attained without any retaining screws.  
Install the draft damper motor using the mounting holes provided, and  
connect the chain to the damper and to the damper motor wheel.  
Leave the bottom chain link open so that it may be disconnected in an  
emergency.  
TW2000  
11  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
8.  
Adjust chain length by squeezing or expanding links with pliers. Adjust  
the chain so that the damper is open to the maximum of 11/16” without  
putting any extra strain on the damper motor.  
9.  
Install the aquastats and complete the wiring, plumbing, smoke pipe  
and fire extinguishing tube installations as shown in the appropriate  
electrical and plumbing diagrams.  
10.  
IMPORTANT: Always test all functions under actual firing conditions  
before leaving the site. Test especially for correct operation of damper,  
limit and by-pass zone valve and circulator.  
Note: If the KERR TW2000 boiler is installed above the radiation level, a low  
water cut off is required. It should be installed on pipe tees positioned at the  
supply and return points of the boiler.  
Never leave start up to the homeowner. Explain the operations thoroughly  
to the operator.  
2.4.1 Combustion Air Supply  
Air inlets of at least 200 square inches free area (1.5 in2/1000Btu) must be  
provided to the room occupied by the wood fired or oil fired boiler. These fresh  
air inlets must provide or allow free access of fresh outside air to the boiler. At  
no time, or under any circumstances can a wood or oil burning appliance, be  
starved of combustion air.  
The appliance must at all times be able to maintain the approved stack draft.  
The barometric draft regulator must be installed on the boiler smoke pipe in the  
same room or at least in such a way that there is unrestricted free passage of air  
between the combustion air inlet to the boiler or burner and the barometric draft  
regulator.  
It is important to provide adequate combustion air to the boiler. It may be  
necessary to add a ventilator to an exterior wall of a closed boiler room or an  
airtight basement.  
Operating a wood or oil fired appliance with inadequate combustion air could be  
hazardous.  
TW2000  
12  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
2.4.2 Flue Pipe and Chimney  
The Boiler must be located to meet a minimum venting distance needed between  
the Boiler and the flue. It should also be ducted so that there is a minimum  
number of elbows used. The flue pipe must be installed with a gradual rise of ½”  
or more per foot from the Boiler to the flue.  
NEVER ALLOW THE SMOKE PIPE TO RUN DOWNHILL TO THE FLUE!  
The smoke pipe and chimney must be at least 7 inches in diameter. The flue  
pipe or a chimney may be of different cross-sectional area than that of the  
appliance smoke pipe, provided that sufficient draft is available at the appliance.  
Space must be provided around the smoke pipe and the back of the Boiler to  
allow easy access for the purpose of cleaning. Smoke pipes must not be lighter  
than 24 gauge black steel. All flue pipe must be securely fastened with at least 3  
sheet metal screws at every joint, and properly supported.  
Always meet or exceed flue pipe clearance specifications - 18” clearance from  
flue pipe to combustibles in all directions.  
Connect the boiler only to an approved chimney suitable for solid fuel appliances  
and capable of venting the products of combustion. The chimney must be  
installed with proper clearances above roof and from adjacent structures and  
trees. If a masonry chimney is used it must be in good condition and be  
equipped with a tile liner. Flue thimble or flue pipe must not extend into the  
chimney flue, as it will reduce the draft.  
Connect only to a flue or chimney capable of maintaining a negative draft of  
between .02”w.c. min. and .05”w.c. max., at all times and conditions. To  
maintain this draft, one or two draft regulators may be required. We recommend  
that the KERR TW2000 Wood-Fired Boiler be connected to its own chimney.  
However, two or more fuel fired appliances, other than fireplaces or incinerators,  
may be connected to the same chimney.  
TW2000  
13  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
The National Standard of Canada, Installation Code for Solid-Fuel-Burning  
Appliances and Equipment, CSA-B365-01 clause 5.2.9 states that:  
Two or more appliances shall not be connected to the same chimney flue unless:  
a.  
b.  
The appliances are located on the same story;  
A negative pressure is maintained at the flue collar of each  
appliance;  
c.  
Each appliance is provided with a means to control the rate of flow  
of air or flue gases through the appliance combustion and heat  
exchanger chambers. Where limitations on flue pressure (draft) are  
contained in the manufacturer’s instructions, such means shall be  
capable of maintaining at the flue collar, the pressure specified by  
the appliance manufacture; NOTE: For the purpose of this Clause,  
draft controls include ash pit air control dampers, dampers or draft  
slides wherever located, over fire and flue key pipe dampers, and  
check draft controls located on or in the flue pipe.  
d.  
The flue pipes of the appliances are connected to a manifold as  
close to the chimney as practicable or directly to the chimney in the  
following order:  
(i) If only solid fuel is used, the flue pipe from the smallest  
appliance shall be on top (downstream);  
(ii) If different fuels are used as permitted in Clause 5.2.7, the oil  
flue pipe shall be on top (downstream); and the solid fuel flue  
pipe on the bottom (upstream); and  
e.  
The chimney flue is capable of venting the flue gas by natural draft  
when all appliances not interlocked to prevent simultaneous firing  
are firing at their maximum rate at the same time.  
WARNING: If this setting is exceeded it could cause a solid fuel fire to burn out  
of control.  
When installing a wood-burning appliance to an existing chimney carefully  
inspect entire chimney for the presence of old inlet holes, which may be  
improperly covered by metal caps or other unacceptable means. Fill any  
openings with brick and mortar to ensure no hazardous openings exist.  
TW2000  
14  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
2.5 Clearances  
The KERR TW2000 Wood-Fired Boiler is to be installed in accordance with the  
National Building Code or local regulations. Allowances front and rear must be  
made for cleaning and servicing.  
Minimum safety clearances to combustibles are:  
Front  
One Side  
Other Side (for rear access)  
Rear  
Above Wood-Fired Boiler  
Flue Pipe to combustible, Boiler & electrical wiring  
Floor  
48”  
6”  
24”  
24”  
24”  
18”  
1220 mm  
152 mm  
610 mm  
610 mm  
610 mm  
457 mm  
Non-Combustible  
These clearances will also allow adequate combustion air to reach the boiler.  
2.6 Plumbing Connections  
There are only two differences between the installation of any conventional hot  
water heating system and those using a Kerr TW2000 boiler – the safety override  
zone valve, and the blow-down extinguishing system. A circulator of at least  
5-G.P.M. capacity must be used in a system using the Kerr TW2000 boiler to  
assure circulation of water.  
The normally open zone valve must be installed to allow a free flow of water in a  
power off situation. Kerr recommends that the valve be placed as shown in Fig.  
TW-1 or Fig. TW- 4. The override zone valve should be on the loop supplying the  
living area on the main floor level (i.e. kitchen – living room). The override loop  
for the safety shall have at least 30 ft. of radiation above the wood boiler. Do not  
use basement loop for the safety override loop, as this will not provide gravity  
flow in a power out situation. This override loop must be capable of dissipating at  
least 10% of the estimated heat output of the Kerr TW2000 boiler in the event  
that the circulation is reduced because of electrical power failure. The safety by-  
pass dump zone shall NOT run through any plastic piping. A deliberate manual  
action shall be required to make the override loop inoperative.  
The blow-down extinguishing system is installed to control the fire in case  
overheating causes excessive pressure in the pressure vessel. The relief valve,  
included, is threaded into the top of the pressure vessel and copper pipe is  
installed from its exhaust to the flange above the loading door on the firebox.  
In addition to its ability to heat the home, this boiler is provided with a domestic  
coil position. A copper coil may be purchased with your boiler or added at a later  
date. It may be utilized as a single water heater or in conjunction with an oil, gas  
or electric heater.  
TW2000  
15  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
2.6.1 Free Standing  
Free Standing installation requires additional components, which are not included  
in the TW2000 boiler kit. Check wiring diagrams TW – 5 and TW – 6 for  
additional required components.  
In the freestanding, or stand-alone system, the Kerr TW2000 boiler is the sole  
source of central heating. In this system connect the piping as you would for any  
conventional hydronic heating system (using zone valves, circulator zoning, or  
single zone flow check system). The boiler must not be installed as a gravity  
system, as the controls are not designed for this type of operation. When  
installing the Kerr TW2000 boiler as a stand-alone system, the boiler may be  
wired in two ways. For the Stand-Alone wiring diagram, Fig. TW-5 a triple  
function aquastat and an additional transformer must be purchased  
separately and installed in place of the dual aquastat supplied with the boiler. An  
alternative Stand-Alone Wiring diagram, Fig. TW-6 is shown, but an additional  
relay and housing must be purchased separately and wired using high  
voltage wire only (using 120v wire on 24v coil also). The only special piping  
needed is the connection of the special safety by-pass zone valve and blow  
down system as described above. For plumbing details see Fig. TW-4.  
2.6.2 Parallel  
In the PARALLEL SYSTEM the water is circulating between the two boilers by  
means of an auxiliary circulator. In this system the flow of water from the existing  
boiler (supply) is teed and piped to the return of the Kerr TW2000 boiler. The  
return pipe to the existing boiler is teed, and piped to the outlet nipple of the Kerr  
TW2000 boiler. Therefore the TW2000 is maintaining heat in both boilers. If the  
TW2000 is not being utilized the system warm return water is not keeping the  
wood boiler warm.  
In the parallel system an auxiliary circulating pump keeps the temperature even  
between the two boilers. It is controlled by a separate aquastat on the Kerr  
TW2000 boiler. When the water in the Kerr TW2000 boiler is hotter than the set  
point of the single aquastat, the circulator comes on and circulates the hot water  
between the two units.  
This system allows the domestic hot water coil in the existing boiler to supply the  
household with hot water without an additional coil in the Kerr TW2000 boiler.  
TW2000  
16  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
2.7 Control System  
The Kerr TW2000 boiler control system serves the following functions:  
1. Maintaining the boiler water temperature by controlling the combustion  
air entering the boiler. A double pole, double throw aquastat and the air  
damper control this function.  
2. Protects the Kerr TW2000 boiler from an overfire by overriding the  
home’s thermostat and by putting any excess heat into the living area.  
Opening the “normally open by-pass zone valve” and turning on the  
circulator accomplish this.  
3. To allow the Kerr TW2000 boiler to operate as a gravity heating  
system in the event of a power failure, the “normally open by-pass  
zone valve” will automatically spring open in a power off situation.  
4. Kerr TW2000 boiler “BLOW-DOWN” fire extinguishing system. In the  
case of extreme over firing the pressure in the boiler will exceed 30  
PSI. When this happens, a relief valve will open and allow steam to  
escape into the firebox area, damping the fire. See Fig. TW-9 showing  
the fitting for the installation of the fire extinguishing system.  
IMPORTANT: Upon completion of the installation, a change over from one fuel to  
the other shall not require manual adjustment of any controls other than the  
thermostat.  
2.8 Wiring  
The wiring diagrams for the controls on the Kerr TW2000 boiler are shown in  
Figures TW-2, 3, 5, and 6. Do not rewire or change the function of the controls on  
an existing boiler when adding a Kerr TW2000 boiler. The electrical systems of  
both boilers must be powered from a single branch circuit without exception.  
NOTE: Most oil-fired boilers utilize a triple aquastat as shown in Fig. TW-2.  
No rewiring is necessary in the oil boiler control.  
To install the boiler as a free standing unit see Fig. TW-4, TW-5 and TW-6.  
NOTE: The aquastat may be marked “High” and “Low” opposite the diagrams.  
The diagrams are correct.  
ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL  
CODES.  
TW2000  
17  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
2.9 DEALER INSTRUCTIONS TO THE HOMEOWNER  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
Keep area around unit clean.  
Use DRY wood only. Hardwood is preferred.  
Load carefully.  
Load level no higher than center of door.  
Remove ash regularly as directed.  
Watch for soot build up in smoke pipe.  
Realize the danger of extreme overheating due to overfiring.  
Danger of flue fire if poor fuel or poor maintenance produces creosote  
buildup.  
9.  
Operation of unit during power failure. (i.e. manual operation of zone  
valves and flow check valves).  
10.  
11.  
When shutting down for extended periods, clean unit thoroughly.  
Apply a light coating of motor oil to inside of boiler and other exposed  
interior surfaces to protect against rust due to moisture from condensation.  
12.  
13.  
14.  
Before reloading the boiler with wood, turn up the thermostat 2 to 3  
minutes prior to loading to establish the draft.  
When reloading rake the ashes toward the front and place the new fuel  
load toward the rear of the boiler.  
If, under poor draft conditions, smoke comes out of the door when  
reloading, the cast iron baffles may be moved forward on the ledge to  
allow a ¾” gap behind the baffles. This will allow smoke over the  
smoldering embers to escape through the gap when the door is opened.  
TW2000  
18  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
2.10 Installers Final Checklist  
PIPING INSPECTION  
1.  
2.  
3.  
4.  
5.  
Boiler plumbed properly?  
Is a 12” x 36” expansion tank or equivalent installed?  
Normally open by-pass zone valve installed?  
Does the normally open zone valve by-pass to the main living area loop?  
Is the normally open zone valve on the most direct piping loop (fewest  
elbows)?  
BOILER INSPECTION  
1.  
2.  
3.  
4.  
5.  
Are clearances maintained?  
Are all firebricks in place in the boiler?  
Is the relief valve piped back into the combustion chamber?  
Is the system full of water and air eliminated?  
Are zone valves and piping located to prevented drips on controls?  
WIRING INSPECTION  
1.  
2.  
3.  
Is main disconnecting switch within view?  
Wiring cables protected from heat and not touching hot surfaces?  
Check normally open zone valve (should heat gravity zone when valve  
open).  
4.  
Check settings on all aquastats.  
FLUE AND SMOKE PIPE INSPECTION  
1.  
2.  
3.  
4.  
5.  
6.  
Flue inner size equivalent to 7” round or larger?  
Separate entry to flue for both solid-fuel and oil or gas smoke pipes?  
Smoke pipe 24 gauge or better?  
Smoke pipe secured by screws?  
Draft regulator (if used) set at .05” w.c. maximum?  
Clearances of smoke pipe 18” or better from combustible material?  
Metal protection is recommended.  
TW2000  
19  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
Parts List For TW 2000  
Heat Exchanger  
H1 – Heat Exchanger  
Front Insert (10” x 8” trapezoid)  
Cabinet  
C1 – Left Side  
C2 – Right Side  
C3 – Top  
Water Coil  
Cast Door  
W1 – K – 26 Domestic Hot Water Coil  
D1 – Gasket (¼” Cerafelt Gasket)  
D2 – Frame  
D3 – Handle Sleeve  
D4 – Handle  
D5 – Door  
D6 – Hinge Bolt  
Baffle  
B2 – Cast Iron Baffles (Four pieces 13 ¾” x 10 ¼”)  
Insulation  
I1 – Cerafelt Board Insulation (Two pieces 19” x 8” x ½”)  
F1 – Fire Brick (Sixteen pieces 9” x 4 ½” x 1 ¼”)  
Safety Devices:  
S1 – Blow-out Feature  
Two ¾”C x ¾”NPT Male Adaptors  
Two ¾” x 90° Elbows  
Two ¾” x 2 ½”Copper pipe  
One ¾” x 12” Copper pipe  
S2 – Pressure Relief Valve (3/4” C335)  
Instrumentation  
T1 – Tridicator  
Dual Aquastat (White Rodgers 11C61-12)  
(Honeywell L6081A1036)  
½” Aquastat well  
Single Aquastat W/well (White Rodgers 1131-012)  
(Honeywell L6006A 1145)  
Damper Motor C/W Chain (Honeywell M847A 1031)  
Transformer 120/24V (Honeywell AT20B 1064)  
N/O Zone Valve (Honeywell V8043D 1239)  
Two Zone Valve Fittings  
Miscellaneous  
Boiler Drain ½”  
¾” Close B.I. Nipple  
1 ¼” x 6” B.I. Nipple  
1 ¼” B.I. Tee  
1 ¼” x ¾” B.I. Bushing  
Draft Regulator  
Clean-out Poker  
Junction Box and 14/3 BX Cable  
TW2000  
20  
10/6/05  
TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL  
TW-2000 Parallel Plumbing Wiring Explanation TW-2  
The wood system neutral is connected to the oil boiler neutral.  
A)  
B)  
The line power for the wood boiler must come from the same power  
disconnect switch as the oil boiler.  
C)  
Single Aquastat (White Rodgers 1131-102)  
Metal 160°F  
This operates the circulation pump to circulate hot water between the two  
boilers when the wood boiler is in operation.  
The N/O contacts on the single aquastat White Rodgers (1131-102)  
should be connected to the secondary circulation pump between the wood  
and oil boilers (as shown in plumbing diagram TW-1).  
D)  
Double Aquastat (White Rodgers 1161-12)  
High Limit Left  
This is the wood high limit. If the water temperature in the wood boiler  
reaches 200°F the wood boiler air damper is closed and the safety by-  
pass zone valve is opened. The end switch on the safety by-pass zone  
valve makes a call for heat on the oil boiler triple aquastat, which starts the  
primary circulator.  
Metal 200°F  
Brass 190°F  
E)  
F)  
Double Aquastat (White Rodgers 1161-12)  
This is used to maintain the wood boiler at the set temperature by opening  
and closing the wood boiler air damper.  
Low Limit Right  
Metal 170°F  
Brass 150°F  
The triple aquastat on the oil boiler controls the oil boiler in the normal  
manner.  
The safety by-pass zone is only shown in plumbing diagram TW-1. The safety  
by–pass dump zone should be plumbed from the wood boiler in the case of high  
limit condition or power outage. This will provide heat to the house by gravity  
flow. The dump zone should be to the largest living area and it should be an area  
above the wood boiler (for gravity flow during a power outage). Also this zone  
shall NOT have any plastic piping such as in-floor heat, because the hot water  
from the wood boiler may damage the tubing.  
The supply from the wood boiler should only be connected to the plumbing  
system after the primary circulator, and in conjunction with a flow check valve on  
the wood supply line. This will not allow hot water to flow through the wood boiler  
when the secondary circulation pump is not in operation (no fire in wood boiler).  
TW2000  
21  
10/6/05  

Westcott 1849 User Manual
Weil McLain SB0002 User Manual
Wayne Dalton Corp. Car Video System 9800 User Manual
Toshiba TEC MA 1900 User Manual
Toshiba BDK21KU User Manual
Timex W 262 184 095000 WW User Manual
Sony NAV U NV U94T User Manual
Sony Discman D E409CK User Manual
Sony DCR PC3 User Manual
Silhouettes DKC646BLS User Manual